Sub-sea equipment test and isolation tool

ABSTRACT

A combined test and isolation tool for sub-sea well equipment is used particularly for testing the integrity of internal sealing surfaces of sub-sea well head housings and also for testing casing hangers and their seals. The same tool is run on drill pipe in a sub-sea well to isolate a casing hanger seal from components of the well blow-out preventer to determine accurately and with finality where a detected leak originates. The use of the tool enables costly well head housings, casing hangers and seals normally discarded following a single usage to be reused with safety and efficiency and at a great savings in cost.

BACKGROUND OF THE INVENTION

The proliferation of sub-sea well drilling operations and the heavy costincident thereto has created an urgent need for economy in many areas.For example, it has been customary to discard some costly equipmentcomponents after a single usage without any effort to salvage and reusethe same. Costly new components are sold to the customer for each newsub-sea drilling operation. Among the components which have beendiscarded after use are well head housings in which costly casinghangers and their seals are disposed. Each casing hanger seal when newcosts as much as $3,000 and the new well head housing costs manythousands of dollars and when used only once represents an extremeeconomic burden on the customer.

This invention has been devised to deal with the above problemcompletely and economically so that the costly practice of discardingwell head housings after only one usage can be eliminated. Moreparticularly, the tool which embodies the present invention has theability to efficiently test the internal sealing surfaces of well headhousings to determine the integrity of such surfaces after usage in asub-sea well, and in almost all cases, the testing indicates that thewell head housing can be safely reused a number of additional times witha correspondingly great saving of money. Additionally, the toolaccording to the invention is used to test sub-sea casing hangers andtheir costly seals. By means of the identical tool, when run on a drillpipe string in a well and actuated with fluid pressure through the drillpipe, a given casing hanger seal can be isolated from blow-out preventerequipment to determine whether the seal is leaking, in which case theseal is replaced, or whether the source of the trouble is somewhere inthe blow-out preventer.

Another very important aspect of the invention resides in the fact thatthe test and isolation tool itself is quite simple and comparativelyeconomical in construction because of the fact that the tool employsdiscarded and slightly altered casing hangers and used casing hangerseals instead of new seals which cost up to $3,000, as stated. Each timea well is drilled at least one seal is used and usually two and theseseals are discarded. The discarded casing hanger seals are the sealsemployed for the tool forming the subject matter of the invention. Whenthe casing hangers are repaired, new seals are always used, and for thesealing surfaces of the hangers to have been tested with used seals andfound to be satisfactory puts even a greater guarantee on the integrityof the surfaces, and this guarantee applies equally to the sealingsurfaces of well head housings which are also tested by used seals onthe test tool. The tool is also capable of testing casing hanger sealssimultaneously with the testing of sealing surfaces on well headhousings and casing hangers. Thus, the invention is very versatileresulting in a further savings of cost to the customer.

The prior art contains a variety of testing tools for well pipe and wellhead equipment and for well casing. The nature and construction of suchtools varies widely depending upon the particular use or application ofthe test tool. Many prior art test tools are for the purpose of testinga full length of pipe or casing for leakage through pin holes, threadsor couplings and not at specific local sealing surfaces, as is the casewith the present invention. Suffice it to say, no known prior art deviceis constructed and arranged to satisfy the specific requirements whichthe present test and isolation tool meets, and to this extent thepresent invention is thought to satisfy a need of the art whichheretofore has not been satisfied by anyone.

To comply with the duty to disclose known prior art under 37 C.F.R.1.56, the following United States patents are made of record herein:

U.S. Pat. Nos. 2,951,363; 3,034,339; 3,048,998; 3,177,703; 3,199,598;3,371,521; 3,478,577 and 3,712,115.

Other features and advantages of the invention will become apparentduring the course of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a composite side elevation of a test and isolation toolembodying the invention with associated handling and plugging elements.

FIG. 2 is an enlarged central vertical longitudinal section through thetool.

FIG. 3 is a horizontal section taken on line 3--3 of FIG. 2.

FIG. 4 is an enlarged fragmentary developed elevational view of tubingfor supplying hydraulic pressure simultaneously to multiple cylinders ofa hydraulic actuator and taken approximately on line 4--4 of FIG. 2.

FIG. 5 is a central vertical section taken through a used casing hangerwhich, after cutting, forms an element of the tool.

FIG. 6 is an enlarged central vertical section through the tool andthrough a used well head housing whose sealing surfaces are beingtested.

FIG. 7 is a side elevation, partly in cross section and partly brokenaway, showing a sub-sea well head and associated equipment with the toolaccording to the invention being employed as an isolation tool.

FIG. 8 is a side elevation, partly in cross section, of the isolationtool connected to drill pipe.

DETAILED DESCRIPTION

Referring to the drawings in detail wherein like numerals designate likeparts, the test and isolation tool proper comprises a tubular mandrel 20having external screw-threads 21 and 22 on opposite end portions thereofto receive nuts 23 and 24 having annular shoulders 25. The tool utilizesa pair of used salvaged conventional casing hangers of the type shown at26 in FIG. 5. Each such casing hanger has one end portion 27 thereofcompletely cut off on a transverse cutting line 28 to provide themodified casing hanger utilized in the test and isolation tool. Suchmodified casing hangers are shown at 29 and 30 in the drawings and,referring to FIG. 2, it will be noted that the elements 29 have theircut-off end faces 28 disposed in end-to-end opposing coaxial spacedrelationship in the tool assembly.

The two modified casing hangers 29 and 30 are located radially of themandrel 20 and are pressure sealed relative to the outer cylindricalsurface of the mandrel by a pair of collars or rings 31 each having aninterior O-ring seal 32 in sealing engagement with the mandrel 20 and anexterior O-ring seal 33 in similar sealing engagement with an interiorcylindrical face 34 of each casing hanger 29 and 30.

Surrounding a cylindrical sealing land 35 on each casing hanger 29 and30 is a conventional used and salvaged annular casing hanger seal 36.Each such seal has an elastic rubber-like body 37 tapering axially inboth directions and being capped on each end of the elastic body 37 bythin lipped metallic seal elements 38 adapted to be forced intometal-to-metal fluid sealing engagement with the lands 35 when theelastic bodies 37 are compressed axially, in a manner to be described.

Means are provided on the tool assembly to activate or energize the twoseals 36 and this means comprises a multiple piston carrier head 39having an annular skirt 40 surrounding the inner end portion of thecasing hanger 29 with the end of the skirt bearing on a rigid annulus 41of one seal 36, such seal having an opposite end rigid annulus 42engaging a rigid shoulder 43 of casing hanger 29. The multiple pistoncarrier head 39 has preferably twelve comparatively small equal diameterand circumferentially equidistantly spaced pistons 44 anchored theretothrough threaded stems 45 on the pistons. The twelve small pistons 44extend axially of the head 39 in surrounding relationship to the mandrel20, as illustrated. The pistons 44 are all of equal length axially.

Mounted in opposing spaced relationship to the piston carrier head 39 isa cylindrical piston head 46 having an integral axially extending skirt47 whose end bears against a rigid annulus 48 of the second seal 36,such seal having another rigid annulus 49 bearing against a rigidannular shoulder 50 of the modified casing hanger 30.

The cylinder head 46 contains preferably twelve circumferentially spacedcylinders 51 sized and spaced to receive the pistons 44 telescopically,for relative reciprocation. Pressurized fluid is delivered into thebottom of each small cylinder 51 below the adjacent piston 44 through asmall fitting 52 on the interior of the cylinder having a connectionwith a serpentine fluid delivery tube 53 of very small diameter. Oneterminal end 54 of this tube receives pressurized fluid from a T-fitting55 which is also coupled to the other terminal end portion 56 of thetube 53. Pressurizing fluid for the several cylinders 51 is delivered tothe fitting 55 through a flex coil 57 which is looped around the mandrel20 in the cavity between the two relatively movable heads 39 and 46.This flex coil allows the necessary relative movement between the heads39 and 46 when the cylinders 51 are pressurized. Due to the arrangementof the tube 53 with fittings 52 and 55, all of the twelve cylinders 51will receive pressurizing fluid simultaneously. Such action will spreadapart the two heads 39 and 46 axially of the mandrel 20 and through theskirts 40 and 47, the elastic bodies 37 of the two seals 36 will becompressed and the thin metal sealing lips 38 of both seals will beactivated or energized during use of the tool for testing or forisolation purposes, FIGS. 6 and 7, as will be further described.

Pressurized fluid to energize the cylinders 51 is delivered through alongitudinal tube 58 extending into the bore 59 of the tubular mandrel20 and equipped outside of the mandrel with a suitable coupling 60 sothat the tube 58 can be coupled with a source of pressurized fluid, notshown. Near the center of the mandrel and tool the tube 58 communicateswith a radial fitting or adapter 61 having screw-threaded engagement at62 in a screw-threaded opening formed in the side wall of mandrel 20.The adapter 61 is sealed effectively relative to the mandrel opening byan O-ring seal 63. The outer end of fitting 61 is coupled through anelbow fitting 64, FIG. 3, with the inlet end of the aforementioned flexcoil 57 which has a coupling 65 thereon for this purpose.

A separate longitudinal tube 66 for seal testing fluid also extendsthrough the mandrel bore 59 and has a coupling 67 at its end beyond themandrel bore for connecting with a source of pressurized fluid. Theother end of tube 66 is connected in the bore 59 with a second radialadapter 68, having threaded engagement as at 69 with the mandrel 20. Theadapter 68 is sealed relative to the mandrel radial opening by an O-ring70, as illustrated. Pressurized test fluid delivered to the adapter 68from tube 66 following energizing of the two seals 36 is delivered tothe space outside of the mandrel 20 and between the two seals 36 via thefitting or adapter 68, FIGS. 2 and 6.

Referring to FIGS. 1 and 2, a plug 71 having an integral loop 72 isadapted to enter internal screw-threads 73 provided in one end of themandrel 20 merely for the purpose of lifting and manipulating the tool,which is quite heavy, with suitable equipment. The opposite end of themandrel contains a threaded opening 74 of reduced diameter adapted to beclosed by a plug 75 when the tool is used as an isolation tool, FIGS. 7and 8.

For testing a retrieved well head housing 76, as shown in FIG. 6, toassure that its two localized internal sealing lands 77 are still secureand able to hold the required pressure so that the housing 76 can besafely reused, the following procedure is carried out. The assembledtool, as described in FIGS. 1 and 2, is placed in the bore of well headhousing 76 undergoing testing of its sealing surfaces 77 and the twoused casing hanger seals 36 of the tool are placed in registration withthe annular sealing surfaces 77. Pressurized fluid is then sent throughthe small tube 58 and adapter 61 to the flex coil 57 and through thiscoil to the fitting 55 and tube or manifold 53 leading to the severalcylinders 51. Since all of the tubing is small in diameter, there is noproblem of it withstanding the high pressures involved. Preferably theseal energizing fluid delivered from the tube 58 is initially at apressure of about 1500 psi which lightly expands the metal lips 38 ofthe two seals 36 against the lands 77 of well head housing 76 and theopposing lands 35 of casing hangers 29 and 30. Following this,pressurized fluid for testing the seals 36 is introduced through thetube 66 somewhat in excess of the pressure in the tube 58. This willproduce leakage around the seals 36 and the desired bleeding of air fromthe space between the two seals. The pressure for energizing the sealsvia tube 58 and for testing via tube 66 is then incrementally increaseduntil the test pressure through the tube 66 reaches about 10,000 psi. Ifthe seals 36 hold this pressure, it is apparent that the sealingsurfaces 77 of the well head housing are perfectly sound and the housingis reusable. In practice, the pressures may be stepped up from theinitial 1500 psi to about 5000 psi and then to 7500 psi and, finally, tothe full test pressure of 10,000 psi. The seal energizing and testpressures in the two tubes 58 and 66 can be equalized in practice withinplus or minus 100-200 psi. The O-rings 32 and 33 of collars 31 assure noleakage around the collars and no leakage can occur around the adapters61 and 68 because of the O-rings 63 and 70.

Since the seals 36 of the testing tool are normally used seals and ifthe test indicates that the sealing lands 77 are secure at the requiredtest pressure, it is all the more clear that when the housing 76 isagain used in a well with new casing hanger seals the lands or surfaces77 will hold. If the housing 76 passes the test and can be used, a greatsavings is effected compared to the cost of a new well head housing, aswill be known to any one skilled in the art.

Still referring to FIG. 6, it should be apparent that the test tool cansimultaneously with the testing of the sealing surfaces 77 test new orused casing hanger seals. Also, the tool can be used to test a regularuncut or unaltered casing hanger of the type shown at 26 in FIG. 5, onehanger at a time merely by changing the configuration of the mandrel andnut from that configuration shown in FIG. 6.

Referring to FIGS. 7 and 8, the use of the tool as an isolation tool isillustrated. For this purpose, the tool is connected directly in drillpipe 78, and the upper internal threads 73 of tubular mandrel 20 arecoupled with mating threads on the lowermost pipe section 78. During theisolation test, the lower threaded opening 74 of the mandrel 20 isplugged by the element 75. The outlet of the test fluid adapter 68 isalso closed or plugged by a plug element 79, FIG. 8. Neither of thetubes 58 and 66 is required for the isolation test and they are removedfrom the adapters 61 and 68. Fluid pressure for activating or energizingthe seals 36 is obtained through the drill pipe 78 and the bore 59 ofthe mandrel and through the adapter 61, flex coil 57 and tube 53connected to cylinders 51, as previously described in detail. Except asdescribed above, the tool assembly remains exactly the same aspreviously described in FIGS. 1 through 6.

In FIG. 7, the isolation tool as shown in FIG. 8 is positioned within anin-place well head housing 80 in the same manner illustrated in FIG. 6so that the two seals 36 of the tool engage the internal sealing lands77 of the well head housing. The well head housing 80 is shownpositioned normally relative to the lower BOP guide frame 81 and abovethe temporary guide base assembly 82 of the sub-sea well. FIG. 7 showsadditional elements of the BOP equipment including a middle BOP guideframe 83 and choke and kill line 84. Other illustrated components areconventional.

As previously stated, during the isolation test, FIG. 7, the seals 36 ofthe test tool are energized by fluid pressure through the drill pipe 78,the bore of mandrel 20, adapter 61 and the described cylinder-pistonarrangement, FIGS. 3 and 4. The results are the same as where the seals36 are energized through the small tube 58 from an external source offluid pressure for testing the well head housing lands 77.

In the isolation test, the test pressure which may be full well headpressure is delivered through the choke and kill line 84 directly intothe open top of well head housing 80, FIG. 7. If the top seal 36 of thetool holds this test pressure without leaking, it is then clear that adetected leak is somewhere in the BOP equipment and not in the seal 36.On the other hand, if the top seal 36 does leak in the isolation test,it can be replaced.

It has now been shown that the versatile and comparatively simple toolhas utility as an isolation tool as well as for testing localizedinternal sealing lands of expensive well head housings to enable theirreuse and also for testing casing hangers and their seals. Theadvantages of the tool over prior art devices should now be apparent tothose skilled in the art.

With final reference to FIG. 2, it can be pointed out that the toolassembly procedure is as follows. The lower nut 23 is threaded onto themandrel 20. The lower modified casing hanger 30 is placed over themandrel and engaged with the shoulder 25. The lower double sealingcollar 33 is then positioned as shown and the lower seal 36 ispositioned. Following this, the cylinder head 46 is assembled over themandrel and the necessary connections between the tubes 58, 57 and 53are made. Next, the piston head 39 is placed on the assembly followed bythe upper modified casing hanger 29 and its seal 36, and finally theupper nut 24 is threaded on the mandrel 20 and tightened to complete theassembly.

It is to be understood that the form of the invention herewith shown anddescribed is to be taken as a preferred example of the same, and thatvarious changes in the shape, size and arrangement of parts may beresorted to, without departing from the spirit of the invention or scopeof the subjoined claims.

I claim:
 1. A test and isolation tool for sub-sea well equipmentcomprising a tubular mandrel, retaining elements on opposite endportions of the mandrel, casing hanger bodies surrounding the mandrelinwardly of and between the retaining elements and having outer endsengaging the retaining elements, fluid sealing collars engaged betweenthe mandrel and casing hanger bodies, expandable casing hanger seals onthe exteriors of the casing hanger bodies adjacent to exterior sealinglands thereof, corresponding ends of said seals abutting rigid shouldersof said casing hanger bodies to prevent displacement of the sealsaxially toward th opposite ends of said mandrel, a piston head includingmultiple circumferentially spaced pistons surrounding said mandrelbetween the casing hanger bodies and including a skirt engaging theinterior end of one casing hanger seal, a coacting axially opposingcylinder head including multiple circumferentially spaced cylinders forsaid multiple pistons, means for delivering seal energizing pressurizedfluid through the bore of said mandrel to all of said cylinders topressurize them and force said piston and cylinder heads apart axiallyfor energizing said casing hanger seals, said cylinder head having askirt engaging the interior end of the other casing hanger seal, andmeans for delivering seal testing pressurized fluid through the bore ofthe mandrel to the space surrounding the mandrel between said seals,whereby said seals may be placed in engagement with axially spacedinternal sealing lands of a used well head housing to test the integrityof such lands.
 2. A test and isolation tool for sub-sea well equipmentas defined in claim 1, wherein said tubular mandrel is externallythreaded on opposite end portions and said retaining elements are a pairof nuts adjustably engaging said threaded end portions of said mandrel,and said nuts having axially opposing annular shoulders engaging theouter ends of said casing hanger bodies.
 3. A test and isolation toolfor sub-sea well equipment as defined in claim 1, and said casing hangerbodies comprising salvaged previously used conventional casing hangerswhich have been cut to cleanly remove corresponding end portions thereofto form said casing hanger bodies, and said casing hanger bodies beingarranged in axially opposing oppositely extending directions in saidtool.
 4. A test and isolation tool for sub-sea well equipment as definedin claim 3, and said casing hanger seals comprising previously usedseals.
 5. A test and isolation tool for sub-sea well equipment asdefined in claim 1, and said piston head and cylinder head beingannular, said multiple pistons and cylinders being comparatively smallin diameter, and said means for delivering seal energizing pressurizedfluid to all of said cylinders including a tube common to said cylindersand having a connection with each cylinder near the bottom thereof.
 6. Atest and isolation tool for sub-sea well equipment as defined in claim5, and said means for delivering seal energizing pressurized fluid toall of said cylinders further including a flex coil of tubing connectedwith said common tool and disposed exteriorly of said mandrel insurrounding relation thereto, a pressurized fluid adapter connected inthe side wall of said mandrel and extending internally and exteriorly ofthe mandrel and being connected to said flex coil of tubing exteriorlyof the mandrel, and another tube extending within the bore of themandrel and coupled with the interior end of said pressurized fluidadapter and adapted for coupling with a pressurized fluid sourceexternally of the mandrel bore and beyond one end of the mandrel.
 7. Atest and isolation tool for sub-sea well equipment as defined in claim1, and said means for delivering seal testing pressurized fluid throughthe bore of the mandrel to the space surrounding the mandrel comprisinga tube extending within the bore of the mandrel and adapted for couplingwith a source of pressurized fluid beyond one end of the mandrel, and apressurized fluid adapter connected through the side wall of the mandreland having its interior end coupled to the last-named tube within thebore of the mandrel and having an exterior test fluid discharge endopening exteriorly of the mandrel side wall into said space surroundingthe mandrel between said seals.
 8. A test and isolation tool for sub-seawell equipment as defined in claim 7, and said pressurized fluid adapterdisposed in a radial opening formed through the tubular mandrel, and anO-ring seal on said adapter within said radial opening.
 9. A test andisolation tool for sub-sea well equipment as defined in claim 6, andsaid pressurized fluid adapter disposed in a radial opening formedthrough the tubular mandrel, and an O-ring seal on said adapter withinsaid radial opening.
 10. A test and isolation tool for sub-sea wellequipment as defined in claim 1, and said fluid sealing collars beingannular rigid collars, and an internal and an external O-ring seal oneach said collar respectively engaging and sealing the exterior surfaceof the mandrel and an interior surface of the adjacent casing hangerbody.
 11. A test and isolation tool for sub-sea well equipment asdefined in claim 1, and the opposite ends of the tubular mandrel beinginternally screw-threaded, a tool handling and lifting threaded plugengageable within one internally threaded end of the mandrel, and athreaded closure plug adapted for engagement in the other internallythreaded end of the mandrel during use of the tool as an isolation toolto enable seal energizing pressure to be delivered directly through thebore of the mandrel from drill pipe coupled with the mandrel.
 12. A testand isolation tool for sub-sea well equipment as defined in claim 11,and an additional plugging means for said means for delivering sealtesting pressurized fluid through the bore of the mandrel during usageof the tool as an isolation tool.
 13. A combination test and isolationtool for sub-sea well equipment comprising a tubular mandrel, anadjustable retaining element on each end of the tubular mandrel, a pairof casing hanger bodies on the mandrel in spaced surrounding relationthereto inwardly of said retaining elements and having outer endssolidly engaging the retaining elements and having inner ends which arespaced apart axially, a pair of sealing collars interposed between theexterior surface of the mandrel and internal surfaces of the casinghanger bodies, a pair of casing hanger seals on and surrounding externalsealing lands of the casing hanger bodies, said seals positioned axiallyon the tool to engage spaced internal sealing lands of a well headhousing, a piston head including multiple circumferentially spaced smallpistons surrounding the mandrel axially inwardly of one casing hangerseal and engaging such seal, an axially opposing cylinder head includingmultiple circumferentially spaced cylinders arranged axially inwardly ofthe other casing hanger seal and engaging the same, means fordelievering seal energizing pressurized fluid through the bore of saidmandrel to all of said cylinders, and means for delivering seal testingpressurized fluid through the bore of said mandrel and through themandrel side wall to the exterior of the mandrel between said seals. 14.A combination test and isolation tool for sub-sea well equipment asdefined in claim 13, and both said means for delivering pressurizedfluid being small diameter tubing means.
 15. A combination test andisolation tool for sub-sea well equipment as defined in claim 14, andsaid small diameter tubing means including a pair of fluid adapterspositioned in openings formed through the mandrel side wall and beingsealed in said openings in a fluid tight manner. .Iadd.
 16. A test andisolation tool for sub-sea well equipment comprising a tool body portionadapted for insertion into a well head housing having spaced internalsurfaces to be tested for leakage, spaced expandable testing seals onthe body portion adapted to register with said surfaces,pressure-responsive means on the body portion operable to expand saidseals into test sealing engagement with said surfaces, a first pressurefluid delivery means on the body portion delivering fluid to saidpressure-responsive means at a pressure somewhat above test pressure andsufficient in magnitude to expand said seals to a degree enabling saidsurfaces to resist leakage under test pressure, and a second pressurefluid delivery means on the body portion separate from and isolated fromthe first delivery means and delivering fluid into a chamber of the bodyportion between said seals and surfaces at said test pressure. .Iaddend..Iadd.
 17. A test and isolation tool as defined in claim 16, and saidpressure-responsive means comprising oppositely axially movingcylinder-piston means on the body portion between said seals andsurfaces. .Iaddend..Iadd.
 18. A test and isolation tool as defined inclaim 17, and spaced rigid abutment means on the body portion at theends of the seals away from the cylinder-piston means and resistingaxial compression of the seals by the cylinder-piston means..Iaddend..Iadd.
 19. A test and isolation tool as defined in claim 18,and the cylinder-piston means including axially oppositely moving rigidseal compressing elements in opposing relationship to the rigid abutmentmeans. .Iaddend..Iadd.
 20. A test and isolation tool as defined in claim19, and the tool body portion comprising a center mandrel around whichsaid seals are disposed in spaced concentric relationship, andadjustable support means for said seals and abutment means on saidcenter mandrel and disposed on opposite sides axially of thecylinder-piston means. .Iaddend..Iadd.
 21. A test and isolation tool asdefined in claim 20, and said support means including seals engagingsaid mandrel on opposite sides axially of the cylinder-piston means tosealingly isolate said chamber so that the latter may effectively holdsaid test pressure. .Iaddend.